Re-Start of Evergreen Nylon Recycling. Shaw Industries, Inc.

Transcription

1 Re-Start of Evergreen Nylon Recycling Shaw Industries, Inc CARE Conference May 3, 2006 Russ DeLozier (706)

2 Nylon Recycling Ev er green (ev er-gren) Adjective: Something that remains perennially fresh, interesting, or well liked. 2

3 Evergreen Closed Loop Recycling 3

4 Evergreen Nylon Recycling initially a JV between Honeywell & DSM Started in late 1999 Shut down in Sept 2001 Poor economics for caprolactam (monomer for N6) Plant s s inability to operate at full rate PC Carpet Collection not the issue! 4

5 Shaw is restarting Evergreen Facility located in Augusta, GA Responsibilities DSM operates the process Shaw provides N6 PC & PI feed supply Shaw owns 100% of the Evergreen asset Plant restart will include a Life Cycle Analysis Shaw will own 100% of of recovered Caprolactam 5

6 Status of Evergreen Nylon Recycling Plant DSM identified substantial process improvements DSM s plant idle procedures were very thorough system integrity and recovery has gone very good Shaw is investing significant funding to implement improvements Resulting process more Flexible and Robust! 6

7 Evergreen Nylon Recycling Plant 7

8 Operational Targets 30MM ppy of world class Caprolactam Requires approx 100M ppy of N6 PC carpet Plant will startup when all systems are fully functional. No targets published until full assessments are complete Since 2001, a great deal of development in PCC Collection has occurred ENR s use of N6 PCC is believed to aid the supply/demand balance of all fiber types Quality and purity of the N6 stream are extremely important! Shaw seeking serious suppliers 8

9 Shaw s Collection Support Patented Sorting Technology Diversity of vertical integrated carpet industry leader Distribution and Transportation Network Regional presence facilitates reverse-logistics Economies of of Scale 9

10 Feed Stock Requirements Quality > 98% N6 PC carpet Level loop / cut pile expected at ENR No N66, Urethane material to ENR No tiles to ENR, but EcoWorx N6 stream is OK A formal quality program in place Extensive testing at supplier & ENR Utilize CarPIDs for supplier sorting Must build quality into every bale! 10

11 CARE instrumental in Re-start Shaw is very please to enter into this great effort Sustainability by design vs. regulation CARE will help maintain focus on all aspects of recycling: Market driven solutions Outlets for all products Identification of serious suppliers Recognition of product / process improvements CRI/CARE support CRITICAL to to achieving sustainability 11

12 Summary Shaw IS re-starting Evergreen 12

13 Challenge 13

14 Summary Shaw IS re-starting Evergreen Evergreen is a Closed-Loop process Collection wasn t t the issue last time it it won t t be this time Plant upgrades will make process more flexible and robust Shaw will own 100% of caprolactam product Shaw actively starting to collect seeking serious collectors Quality is essential CARE is vital part of the process! Let s s have a great time! 14

15 Waste-to Energy and Other Shaw Environmental Initiatives 2006 CARE Conference May 3, 2006 Steve Bradfield 15

16 Carpet Gasification Unit in Dalton, GA Partnership with Siemens Building Automation & Technology Clark Wiedetz, Business Dev Mgr for Energy & Environ Solutions First gasification facility in carpet industry Will provide 50,000 lbs/ hr. of steam to Plant 81 dyeing operations ons Designed to utilize up to 16,000 tons/yr carpet waste and 6000 tons/yr t of wood flour from laminate operations Primary steam source for plant allows reduced use of coal-fired boilers Savings of over $1 million/ yr. (avoids volitility of natural gas prices) Served by Shaw PC Carpet Collection System Gets Shaw largely out of Dalton landfill and will also utilize PC P C carpet waste Featured in WSJ article and CNBC video 16

17 Carpet Gasification Unit in Dalton, GA Environmental Benefits Gasification leaves greenhouse gas pollutants in the ash as synthetic gas liberated for combustion. Expect emissions profile similar to natural gas Carpet waste has same pound for pound BTU range as coal Nearing end of final testing phase. Fully operational. Plans to extend technology to other Shaw locations that may include cogeneration. Enhances efficiency and lowers cost of PC carpet collection Important step in recovering energy value, collecting all carpet types, and providing access to sorted materials for higher value uses. Transitional strategy in Shaw s s cradle to cradle efforts. 17

18 EcoWorx Carpet Tile Introduced in 1999 Market success allowed Shaw to completely exit PVC by end of Fastest growing part of Shaw s s business Presidential Green Chemistry Award 2003 Design For Sustainability Award from Society of Plastics Engineers 2006 Every backing and nylon 6 input over 100 ppm tested and optimized under MBDC toxicity protocol for human and environmental health and safety. Supply chain energy 3x lower than the Permabac PVC product it replaced, with 30% reduction in backing mass (3 rd party LCI) 18

19 EcoWorx Carpet Tile Collection Utilizes same PC collection system as Evergreen and WTE PC thermoplastic polyolefin backing and nylon 6 fiber separated mechanically in Cartersville, GA Backing fraction sized and returned to EcoWorx backing extrusion. Nylon 6 fraction to be campaigned at Evergreen to recover EcoWorx co-product. (No compatibility issues.) Campaigning important for recovery of EcoWorx broadloom now under development. Same backing and fiber pathways as tile. EcoWorx limited to PI content until first generation polymer returned under Shaw Environmental Guarantee.. Significant PC returns expected to begin in

20 Cradle to Cradle Redesign EcoWorx broadloom will offer a sustainable thermoplastic high performance broadloom with high tuft bind unaffected by water with pattern match and recovery similar to SBR latex with lightest high performance broadloom weight with same collection and recycling system as SBR broadloom, but campaigned backing recovered for reuse in tile. EcoLogix polyester cushion backing for tile Produced in acquired Synthetic Industries facility High PC recycled content from Sprite bottles Laminated to greige goods with EcoWorx polymer Working toward delamination technology to allow recycling 20

21 Other Environmental Developments: EMS Program Shaw began certification of its manufacturing facilities under an a ISO compliant self-certification program in January of New EMS called Shaw Environmental System (SES),builds on Shaw ISO 9001 compliant quality management system (SQS). Shaw will have 52 manufacturing facilities certified or scheduled for certification by the end of (52 mfg facilities in 24 months) Plant 15, carpet tile facility, scheduled for third-party certification by BSI as a system check for SES. 21

22 Industry Environmental Issues Suggested recycled content incentives under CARE. Direct insertion ion and discussion of equivalence of mass balance (averaging). Particularly important for solution dyed fiber recycled content claims that vary by color. Important for tracking the molecular level blending of caprolactam am found in Evergreen and other carpet materials where direct insertion tracking problematic. Linking credits to market value (i.e. the same conditions approved for carbon credits applied to recycled materials) Application to CARE, LEED, and SCAS. Reporting of multiple environmental impacts on a standard spider diagram format to show comparative impact reductions in addition to recycled content. Provide a more complete environmental snapshot without de-emphasizing emphasizing CARE goals. Show effects of recycled carpet materials kept out of landfills, but recycled into noncarpet products. Create a single industry report card that incorporates CARE s mission. 22

23 EVERGREEN NYLON RECYCLING Recycling Nylon 6 Post-consumer Not just Green, Closed Caprolactam Carpet CARE Recovery Environmental. EVERGREEN Sustainable Stewardship Loop Recycling